Iso 10218-2:2011(E)

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First edition 2011-07-01

Robots and robotic devices — Safety requirements for industrial robots — Part 2: Robot systems and integration

Robots et dispositifs robotiques — Exigences de sécurité pour les robots industriels — Partie 2: Systèmes robots et intégration

Reference number ISO 10218-2:2011(E)

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Contents Page

Foreword ...... iv Introduction...... v 1 Scope ...... 1 2 Normative references...... 1 3 Terms and definitions ...... 2 4 Hazard identification and risk assessment...... 4 4.1 General ...... 4 4.2 Layout design ...... 5 4.3 Risk assessment ...... 6 4.4 Hazard identification ...... 8 4.5 Hazard elimination and risk reduction ...... 9 5 Safety requirements and protective measures ...... 9 5.1 General ...... 9 5.2 Safety-related control system performance (hardware/software)...... 9 5.3 Design and installation ...... 10 5.4 Limiting robot motion ...... 14 5.5 Layout...... 16 5.6 Robot system operational mode application...... 17 5.7 Pendants...... 21 5.8 Maintenance and repair ...... 22 5.9 Integrated manufacturing system (IMS) interface...... 23 5.10 Safeguarding...... 24 5.11 Collaborative robot operation ...... 32 5.12 Commissioning of robot systems ...... 35 6 Verification and validation of safety requirements and protective measures ...... 36 6.1 General ...... 36 6.2 Verification and validation methods...... 37 6.3 Required verification and validation ...... 37 6.4 Verification and validation of protective equipment...... 37 7 Information for use...... 38 7.1 General ...... 38 7.2 Instruction handbook...... 39 7.3 Marking...... 43 Annex A (informative) List of significant hazards ...... 44 Annex B (informative) Relationship of standards related to protective devices...... 47 Annex C (informative) Safeguarding material entry and exit points...... 49 Annex D (informative) Operation of more than one enabling device ...... 52 Annex E (informative) Conceptual applications of collaborative robots ...... 53 Annex F (informative) Process observation...... 55 Annex G (normative) Means of verification of the safety requirements and measures...... 58 Bibliography...... 71

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Foreword

ISO (the International Organization for Standardization) is a worldwide federation of national standards bodies (ISO member bodies). The work of preparing International Standards is normally carried out through ISO technical committees. Each member body interested in a subject for which a technical committee has been established has the right to be represented on that committee. International organizations, governmental and non-governmental, in liaison with ISO, also take part in the work. ISO collaborates closely with the International Electrotechnical Commission (IEC) on all matters of electrotechnical standardization.

International Standards are drafted in accordance with the rules given in the ISO/IEC Directives, Part 2.

The main task of technical committees is to prepare International Standards. Draft International Standards adopted by the technical committees are circulated to the member bodies for voting. Publication as an International Standard requires approval by at least 75 % of the member bodies casting a vote.

Attention is drawn to the possibility that some of the elements of this document may be the subject of patent rights. ISO shall not be held responsible for identifying any or all such patent rights.

ISO 10218-2 was prepared by Technical Committee ISO/TC 184, Automation systems and integration, Subcommittee SC 2, Robots and robotic devices.

ISO 10218 consists of the following parts, under the general title Robots and robotic devices — Safety requirements for industrial robots:

⎯ Part 1: Robots

⎯ Part 2: Robot systems and integration

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Introduction

This part of ISO 10218 has been created in recognition of the particular hazards that are presented by industrial robot systems when integrated and installed in industrial robot cells and lines.

Hazards are frequently unique to a particular robot system. The number and types of hazards are directly related to the nature of the automation process and the complexity of the installation.

The risks associated with these hazards vary with the type of robot used and its purpose and the way in which it is installed, programmed, operated, and maintained.

For the purpose of understanding requirements in this part of ISO 10218, a word syntax is used to distinguish absolute requirements from recommended practices or suggested actions. The word “shall” is used to identify requirements necessary for compliance with this part of ISO 10218. Such requirements have to be accomplished unless an alternative instruction is provided or a suitable alternative is determined by a risk assessment. The word “should” is used to identify suggestions, recommended actions or possible solutions for requirements, but alternatives are possible and the suggested actions are not absolute.

In recognition of the variable nature of hazards with the application of industrial robots, this part of ISO 10218 provides guidance for the assurance of safety in the integration and installation of robots. Since safety in the use of industrial robots is influenced by the design of the particular robot system, a supplementary, though equally important, purpose is to provide guidelines for the design, construction and information for use of robot systems and cells. Requirements for the robot portion of the system can be found in ISO 10218-1.

Providing for a safe robot system or cell depends on the cooperation of a variety of “stakeholders” – those entities that share in a responsibility for the ultimate purpose of providing a safe working environment. Stakeholders may be identified as manufacturers, suppliers, integrators and users (the entity responsible for using robots), but all share the common goal of a safe (robot) machine. The requirements in this part of ISO 10218 may be assigned to one of the stakeholders, but overlapping responsibilities can involve multiple stakeholders in the same requirements. While using this part of ISO 10218, the reader is cautioned that all of the requirements identified may apply to them, even if not specifically addressed by “assigned” stakeholder tasks.

This part of ISO 10218 is complementary and in addition to ISO 10218-1, which covers the robot only. This part of ISO 10218 adds additional information in line with ISO 12100 and ISO 11161, International Standards for requirements to identify and respond in a type-C standard to unique hazards presented by the integration, installation and requirements for use of industrial robots. New technical requirements include, but are not limited to, instructions for applying the new requirements in ISO 10218-1 for safety-related control system performance, robot stopping function, enabling device, programme verification, cableless pendant criteria, collaborating robot criteria and updated design for safety.

This part of ISO 10218 and ISO 10218-1 form part of a series of standards dealing with robots and robotic devices. Other standards cover such topics as integrated robotic systems, coordinate systems and axis motions, general characteristics, performance criteria and related testing methods, terminology, and mechanical interfaces. It is noted that these standards are interrelated and also related to other International Standards.

For ease of reading this part of ISO 10218, the words “robot” and “robot system” refer to “industrial robot” and “industrial robot system” as defined in ISO 10218-1.

Figure 1 describes the relationship of the scope of machinery standards used in a robot system. The robot alone is covered by ISO 10218-1, the system and cell is covered by this part of ISO 10218. A robot cell may include other machines subject to their own C level standards, and the robot system can be part of an integrated manufacturing system covered by ISO 11161 which in turn can also make reference to other relevant B and C level standards.

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Figure 1 — Graphical view of relationships between standards relating to robot system/cell

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INTERNATIONAL STANDARD ISO 10218-2:2011(E)

Robots and robotic devices — Safety requirements for industrial robots — Part 2: Robot systems and integration

1 Scope

This part of ISO 10218 specifies safety requirements for the integration of industrial robots and industrial robot systems as defined in ISO 10218-1, and industrial robot cell(s). The integration includes the following: a) the design, manufacturing, installation, operation, maintenance and decommissioning of the industrial robot system or cell; b) necessary information for the design, manufacturing, installation, operation, maintenance and decommissioning of the industrial robot system or cell; c) component devices of the industrial robot system or cell.

This part of ISO 10218 describes the basic hazards and hazardous situations identified with these systems, and provides requirements to eliminate or adequately reduce the risks associated with these hazards. Although noise has been identified to be a significant hazard with industrial robot systems, it is not considered in this part of ISO 10218. This part of ISO 10218 also specifies requirements for the industrial robot system as part of an integrated manufacturing system. This part of ISO 10218 does not deal specifically with hazards associated with processes (e.g. laser radiation, ejected chips, welding smoke). Other standards can be applicable to these process hazards.

2 Normative references

The following referenced documents are indispensable for the application of this document. For dated references, only the edition cited applies. For undated references, the latest edition of the referenced document (including any amendments) applies.

ISO 4413, Hydraulic fluid power — General rules and safety requirements for systems and their components

ISO 4414, Pneumatic fluid power — General rules and safety requirements for systems and their components

ISO 8995-1, Lighting of work places — Part 1: Indoor

ISO 9946, Manipulating industrial robots — Presentation of characteristics

ISO 10218-1, Robots and robotic devices — Safety requirements for industrial robots — Part 1: Industrial robots

ISO 11161, Safety of machinery — Integrated manufacturing systems — Basic requirements

ISO 12100, Safety of machinery — General principles for design — Risk assessment and risk reduction

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ISO 13849-1:2006, Safety of machinery — Safety-related parts of control systems — Part 1: General principles for design

ISO 13850, Safety of machinery — Emergency stop — Principles for design

ISO 13854, Safety of machinery — Minimum gaps to avoid crushing of parts of the human body

ISO 13855, Safety of machinery — Positioning of safeguards with respect to the approach speeds of parts of the human body

ISO 13856 (all parts), Safety of machinery — Pressure-sensitive protective devices

ISO 13857, Safety of machinery — Safety distances to prevent hazard zones being reached by upper and lower limbs

ISO 14118, Safety of machinery — Prevention of unexpected start-up

ISO 14119, Safety of machinery — Interlocking devices associated with guards — Principles for design and selection

ISO 14120, Safety of machinery — Guards — General requirements for the design and construction of fixed and movable guards

ISO 14122 (all parts), Safety of machinery — Permanent means of access to machinery

IEC 60204-1, Safety of machinery — Electrical equipment of machines — Part 1: General requirements

IEC 61496-1, Safety of machinery — Electro-sensitive protective equipment — Part 1: General requirements and tests

IEC 61800-5-2, Adjustable speed electrical power drive systems — Part 5-2: Safety requirements — Functional

IEC/TS 62046, Safety of machinery — Application of protective equipment to detect the presence of persons

IEC 62061:2005, Safety of machinery — Functional safety of safety-related electrical, electronic and programmable electronic control systems

3 Terms and definitions

For the purposes of this document, the terms and definitions given in ISO 10218-1 and ISO 12100 and the following apply.

3.1 application intended use of the robot system, i.e. the process, the task and the intended purpose of the robot system

EXAMPLE Spot welding, painting, assembly, palletizing.

3.2 collaborative robot robot designed for direct interaction with a human within a defined collaborative workspace (3.3)

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3.3 collaborative workspace workspace within the safeguarded space where the robot and a human can perform tasks simultaneously during production operation

3.4 control station part of the robot system which contains one or more control devices intended to activate or deactivate functions of the system or parts of the system

NOTE The control station can be fixed in place (e.g. control panel) or movable (e.g. control pendant).

3.5 distance guard guard that does not completely enclose a danger zone, but which prevents or reduces access by virtue of its dimensions and its distance from the danger zone

EXAMPLE Perimeter fence or tunnel guard.

3.6 integration act of combining a robot with other equipment or another machine (including additional robots) to form a machine system capable of performing useful work such as production of parts

NOTE This act of machine building can include the requirements for the installation of the system.

3.7 integrator entity that designs, provides, manufactures or assembles robot systems or integrated manufacturing systems and is in charge of the safety strategy, including the protective measures, control interfaces and interconnections of the control system

NOTE The integrator can be a manufacturer, assembler, engineering company or the user.

3.8 integrated manufacturing system IMS group of machines working together in a coordinated manner, linked by a material-handling system, interconnected by controls (i.e. IMS controls), for the purpose of manufacturing, treatment, movement or packaging of discrete parts or assemblies

[ISO 11161:2007, definition 3.1]

3.9 industrial robot cell one or more robot systems including associated machinery and equipment and the associated safeguarded space and protective measures

3.10 industrial robot line more than one robot cell performing the same or different functions and associated equipment in single or coupled safeguarded spaces

3.11 safe state condition of a machine or piece of equipment where it does not present an impending hazard

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3.12 simultaneous motion motion of two or more robots at the same time under the control of a single control station and which may be coordinated or synchronous using a common mathematical correlation

3.13 space three dimensional volume

3.13.1 operating space operational space portion of the restricted space (3.13.2) that is actually used while performing all motions commanded by the task programme

NOTE Adapted from ISO 8373:1994, definition 4.8.3.

3.13.2 restricted space portion of the maximum space restricted by limiting devices that establish limits which will not be exceeded

NOTE Adapted from ISO 8373:1994, definition 4.8.2.

3.13.3 safeguarded space space defined by the perimeter safeguarding

3.14 validation confirmation by examination and provision of objective evidence that the particular requirements for a specific intended use are fulfilled

3.15 verification confirmation by examination and provision of objective evidence that the requirements have been fulfilled

4 Hazard identification and risk assessment

4.1 General

4.1.1 The operational characteristics of robots can be significantly different from those of other machines and equipment, as follows: a) robots are capable of high energy movements through a large operational space; b) the initiation of movement and the path of the robot arm are difficult to predict and can vary, for example due to changing operational requirements; c) the operating space of the robot can overlap a portion of other robots' operating space or the work zones of other machines and related equipment; d) operators can be required to work in close proximity to the robot system while power to the machine actuators is available.

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4.1.2 It is necessary to identify the hazards and to assess the risks associated with the robot and its application before selecting and designing appropriate safeguarding measures to adequately reduce the risks. Technical measures for the reduction of risk are based upon the following fundamental principles: a) the elimination of hazards by design or their reduction by substitution; b) preventing operators coming into contact with hazards or controlling the hazards by achieving a safe state before the operator can come into contact with it; c) the reduction of risk during interventions (e.g. teaching).

4.1.3 The realization of these principles can involve: a) designing the robot system to allow tasks to be performed from outside the safeguarded space; b) the creation of a safeguarded space and a restricted space; c) provision of other safeguards when interventions have to occur within the safeguarded space.

4.1.4 The type of robot, its application and its relationship to other machines and related equipment will influence the design and the selection of the protective measures. These shall be suitable for the work being done and permit, where necessary, teaching, setting, maintenance, programme verification and troubleshooting operations to be carried out safely.

4.2 Layout design

The design of the robot system and cell layout is a key process in the elimination of hazards and reduction of risks. The following factors shall be taken into account during the layout design process. a) Establishing the physical limits (three dimensional) of the cell or line, including other parts of a larger cell or system (integrated manufacturing system):

1) scale and origin for modelling the layout in design drawings;

2) location and dimensions of the components within available facilities (scale). b) Workspaces, access and clearance:

1) identifying the maximum space of the robot system, establishing restricted and operating spaces, and identifying the need for clearances around obstacles such as building supports;

2) traffic routes (pedestrian aisles, visitor routes, material movement outside the perimeter safeguarding of the cell or line);

3) access and safe pathway to support services (electricity, gas, water, vacuum, hydraulic, ventilation) and control systems;

4) access and safe pathway for service, cleaning, troubleshooting and maintenance purposes;

5) cables/other hazards for slips, trips and falls;

6) cable trays. c) Manual intervention – the layout should be designed to allow tasks requiring manual intervention to be performed from outside the safeguarded space. Where this is not practicable and when the intervention requires powered movements of the machine(s), appropriate enabling devices shall be provided. The enabling devices may be designed to control:

1) the whole robot cell;